Refractory block and structure



June 7, 1938. p 5 M. c. NEIL v i 3 0,0 Y REFRACTORY 131.001: IIANDSTRUCTURE Filed July 31, 1936 '3 Sheets-Sheet 1 T 1 wfrayerzfpr 1 Q1:ZarX'CTJQZ'Z June 7, 1 938. M, c, NElL 2,120,000

REFRACTORY BLOCK AND STRUCTURE Filed July 31, 1936 3 Sheets-Sheet 2 June7,1938. v c. NEIL 20,

REFRACTORY BLOCK AND STRUCTURE V Filed July 51, 1936 s Sheets-Sheet 5'jreyerfazi Jay/ c? fizz Patented June 7, 1938 UNITED STATES PATENTOFFICE Mark O. Neil, River Forest, Ill. Application July 31, 1936,Serial No. 93,551

18 Claims.

My invention relates to an improvement in liner blocks for stacks andthe like and toan improved stack structure formed by said blocks.

Another purpose is the provision of improved 'means for securing a stackliner in position.-

Another purpose is the provision of an improved arrangement of interiorducts in a stack whereby outside air is pre-heated by the heated gasespassing through the stack and at the same time serves as means forcooling the stack and the stack lining.

Other objects will appear-from time to time in the course of thespecification and claims.

I illustrate my invention more or less diagrammatically in theaccompanying drawings where Figure 1 is a vertical section through astack;

Figure 2 is a section on the line 2-2 of Figure 1;

Figure 3 is a horizontal section through the stack and liner wall, on anenlarged scale;

Figure 4 is a section on the line 4-4 of Figure 3;

Figure 5 is a bottom viewof a liner block; Figure 6 is a detail of asupporting hanger; Figure 7 is a vertical section taken substantiallyalong the line 'l---! of Figure 1, illustrating the air passages andshowing the liner structure; Figure8 is a perspective view of one of theblock portions; and

Figure 9 is a perspective view of a filler block.

Like parts are indicated by like symbols throughout the specificationand drawings.

l indicates any suitable foundation upon which a stack base structure 2may be positioned, the

details of which form no part of the present invention. 3 indicates theouter shell of the stack herein shown as a cylindrical metal shell. Itwill be understood, however, that various shapes may be employed, eithercurvilinear or rectangular in cross section, and that various materialsmay be employed, such as brick and the like.

4 indicates a hot air collecting header connected to the stack structureby a plurality of air outlet passages 5. 6 is a pre-heated air ductextending from the header 4 to any suitable point of use such as afurnace or the like, not herein shown. A plurality of outside air'inletsare indicated in the form of downwardly turned elbows '50 I. The portionof the stack which relates particularly to this invention is the portionextending generally from the header 4 to the inlets 1, which is belowdescribed.

; 8 is any suitable angle iron or abutment for supporting the lining ofthe upper portion of the lower portion indicated at B in Figure 7. Eachportion includes an inner face member l5 and an outer face member l6.These two face members are connected by connecting portions H, for theupper blocks, and Ha for the lower blocks, which combine to form aconnector for the assembled blocks which is generally oval orstreamlined in vertical cross section, as shown for example in Figure 7.

The inner surface portion i5 is preferably somewhat longer than theouter surface portion l6, as shown for example in Figure 5. In order toprovide close joints, I employ tongues i8 and grooves l9, if desired,the tongue and groove structure having the advantage of forming a verytight air lock, especially when the blocks are cemented into place, insuch fashion that air from the air lane l0 cannot escape to the interiorofthe stack, nor can heated gases from the interior of the stackpenetrate to the air lane.

It will be observed, for example in Figures 3, 5 and 8, that the innerface portion I5 is generally arcuate as is the outer face portion l6,and that the two portions are generally concentric. This is anadvantageous form for employment in stacks which are cylindrical or ovelin cross section and may be varied to suit the form of the stack in theevent that stacks bounded by rectilinear walls are employed.

The rear face portion I6 is provided with shoulders 20 which conform tolateral extensions 22 of the spacer blocks generally indicated at .2!and shown in detail in Figure 9. It will be understood that when blocksof the form shown in Figure 8 are assembled, as in Figure 3, the innerface portions l5 abut against each other and are tightly connected bythe tongues l8 and grooves I9 and whatever plaster or cement 24 may beemployed to close the joint. The outer face portions l6, however, arespaced apart and this space is closed by the fillers or spacers 2|, sothat the particular passage or portion of the air line It) which isdefined by any particular group of blocks A and B is completed on theoutside, by the,

spacer or filler blocks 2li I find it advantageous to support the blocksupon the shell 3 by means of a plurality of hangers as shown for examplein Figures 4 and 6. Each hanger, generally indicated at C, includes abase portion 25 which may be bolted to the inner face of the shell 3,for example by bolts 26 and exterior nuts 21. The bolt head may bereceived in a recess 28 in thebase member 25. Extending inwardly fromthe lower edge of the base 25 I illustrate a shelf portion 29 and avertical web 30 terminating in a T 3]. A further reinforcement 32 may beemployed if desired. The structure is preferably aunitary casing of anysuitable metal, and is of sufhcient strength to support a verysubstantial weight.

While under some circumstances it may be advantageous to have a hangerfor each block, I find that in practice an emcient arrangement is tospace the hangers fairly widely apart. I

1) illustrate, for example, in Figure '7 an arrangemerit in which thehangers are arranged in rows, there being a row of hangers, for example,for every fourth row of blocks, there being a hanger for every alternateblock for each such row. It will be understood, of course, that thespacing of said hangers may be varied to suit individual installations.This leaves, as shown in Figure '7, one or more intermediate rows ofblocks without hangers. In order to bury the hanger in the mass of theconnector l1, and to insulate it from the heated air which passes alongthe air lane I0, I preferably position the hangers only in the upperportion A of each block.

The blocks which engage the hangers are cored out or apertured toconform to the hanger in shape, as shown for example in Figures 4 and 5.An enlarged bottom aperture 35 receives the shelf 29. A verticalaperture 36 receives the web 30 and the portion 32. It is provided witha cross aperture 31, to receive the T 3|. An elongated groove 38provides clearance for the bolt head of the securing bolt 26. When theblock portion is dropped into position upon the hanger, downwardmovement is prevented by the shelf 29. Lateral movement along the arc ofthe stack is prevented by the cross piece or T 3|. When other blocks arepositioned above the blocks so held, it is firmly positioned in relationto the structure. However, referring to the liner as a whole, the weightis supported at a large number of points from the shell of the stack,and cumulative load is prevented.

Assume that the stack shell is in position, the structure given at thebottom and the bottom blocks may be supported directly upon the baseportion 2. Each row of blocks is staggered and the blocks are assembledwith the filler blocks 2| dropped or positioned in place as shown inFigure 3. Each filler 2|, is shown in Figure 4, rests directly upon thetop block portion A beneath it, and is covered by the bottom blockportion 13 of the block next above it. The joints may be cemented orplastered in the usual way and since the front portions l are shown asconnected by a tongue or groove connection l8 and I9, and since theportions l6 and 21 are offset to overlap each other, very tight jointsare provided for the air lane III.

A very advantageous feature of my construction rests in the fact that inthe event that any of the blocks burn out or crack, a localized portionof the lining can be removed and separately replaced. The workman inthat case preferably knocks out one of the intermediate blocks which isnot provided with a hanger. Knocking out one such block does not loosenor release the blocks above it, as there is a bridge or arch effeetbetween adjacent hangers. if the block marked X in Figure '7 wereremoved, the blocks Y and Z above it are still supported by the adjacenthangers, and the intermediate filler block 2|, gripped between theblocks Y and Z, is presumably still cemented to them, and serves as aspecies of keystone. Also, the weight or engagement of the tier ofblocks above Y and Z would prevent them from dropping. The workman canknock out as many blocks as necessary, and then reinsert new blocks.

Where hanger engaging blocks are removed, enough space has to beprovided above the hanger so that a new hanger block can be lowered intoplace on the hanger. The various blocks are positioned in place just aswhen the liner was under construction in the first place, except thatwhen the workman comes to the last block, and if a tongue and grooveconnection is employed, he has to knock off the tongue of the last blockand the tongue of the block adjacent to it, to permit the last block tobe inserted into the aperture left for it. In connection with insertingand removing blocks, it is important that the width of the outer faceportion l6 be somewhat smaller than the width of the aperture to befilled by the block and closed by the inner face portion I5.

In the particular stack structure shown in Figures 1 and 2, outside airis admitted through the elbows 1 and through any suitable passages Iainto the interior of the airjlane. Any suitable apertures in the topblocks may be provided to admit this air; The air then blows downwardlythrough the. air lane and out through the bottom passages 5 into the hotair collecting header 4.

It will be realized that whereas I have described and shown a practicaland operative device, and a practical and operative form of block,nevertheless many changes may be made in size, shape, number anddisposition of parts without departing from the spirit of my invention.I therefore wish my description and drawings to be taken as in a broadsense illustrative or diagrammatic, rather than as limiting me to myprecise showing.

In particular, it will be realized that whereas I have shown blocksformed for use in a stack of generally cylindrical cross section,similar blocks may be employed to a rectilinear wall structure. Thetongue and groove connection is preferable but is not under allcircumstances I necessary. The details or shape of the blocks can beconsiderably varied and hangers of varying form may be employed.however, that the hangers be so formed as to provide support for theblocks and to prevent inwarddisplacement of the blocks." It will beunderstood also that my structure may b ployed in connection with a widevariety of dif- It is important,"

For example,

ferent designs of stacks and the like, and the direction of air flow maybe varied.

arranged as to cause circulation in any direction desired.

Whatever the arrangement of the air inlet and air outlet,'thepre-heating effect is increased by the staggered relationship of theblocks and particularly of the connectors II. This is illustrated indetail in Figure 7 and indicates that the air in passing through thepre-heating portion of the stack must take a tortuous path following theair lane HI. This has the advantage of giving to the air a scrubbing'?action. In other words, the air in passing moves or scrubs" against theconnectors. Experience has shown that the air is more readily heated byits impingement or scrubbing" than by radiation or otherwise. Where thepassages are straight or only slightly inclined or curved, it ispossible for relatively quiet zones to develop and these zones form ineffect insulation so that the main body of the air is not effectivelyheated. The staggered relationship shown prevents the formation of theserelatively quiet zones and compels the impingement or scrubbing action.

The connectors are relatively stream-lined to avoid undue resistance andby means of this stream-lining the area of hot refractory exposed in theair lane is thereby greater than the inner face area of the blocksexposed to the hot gases in the chimney or furnace. The result of thisdesign is to, make a refractory heat exchanger of special efllciency andto reduce the tendency of the lining to burn out by maintaining theblock at a temperature at which its mechanical strength is perfectlyadequate for the strains to which it is submitted, and further reducingthe strain set up due to expansion and contraction through heating andcooling.

I claim:

1.'As.a new article of manufacture, a refractory block for furnaces orthe like which includes an outside face portion, an inside face portion,and a connecting spacer portion between the said two portions ofsubstantially smaller cross section than either, the length of saidspacer portion being substantially greater than the thickness of theoutside and inside face portions, the outer faces of the two portionsbeing arcuate and generally concentric, the face of the inside faceportion extending through a substantially greater angle of arc than theface of the outside face portion.

2. As a new article of manufacture, a refractory block for furnaces orthe like which includes an outer portion, an inner portion, and aconnecting member connecting said portions, said outer portion andconnecting member being provided with an aperture adapted to receive asup porting member, said aperture including a vertical portion parallelwith the axis of the connecting member, and a transverse portion incommunication therewith.

3. In a refractory block structure for furnaces and the like, an innerportion, an outer portion, and connecting means therefor, said outerportion being provided with an aperture adapted to receive a supportingmember, said aperture including a bottom recess, a vertical portionprojecting upwardly therefrom and in communication therewith, and atransverse portion in communication with said vertical portion andrecess.

4. As a new article of manufacture, a refractory block for furnaces orthe like which includes an inner face portion, and a radial connectingspacer portion between the inner and outer portions, centrally locatedbetween the ends of the block, and of substantially smaller crosssection than eitherthe inner or outer face portions, and ofsubstantially greater length than the thickness of either the outer orinner portions, the inner portion being of substantially greater widththan the outer, measured transversely of the spacer.

5. As a new article of manufacture, a refractory block for furnacesorvthe like which includes an outer portion, an inner portion, and aconnecting member centrally located between the ends of the blockconnecting said portions, said outer portion and connecting member beingprovided with an aperture adapted to receive a supporting member, saidaperture being midway between the ends of the block.

6. In a refractory block structure, a pair of adjacent refractoryblocks, each including an outside face portion, an inside face portion,and an integral connecting spacer portion between the two portions, anda separate spacer member interposed between the opposite edges of theoutside face portions only, its outer face lying flush with the face of'the outside face portion.

7. In a refractory block structure, a plurality of refractory blocks,each such block including two separable parts, one superposed upon theother, each such part including an outside face portion, an inside faceportion, and an integral connecting spacer portion between the twoportions, and separate spacer members interposed between the oppositeedges of the outside faceportions only, said refractory blocks beingarranged in generally arcuate arrangement, the outer faces of saidspacer members being flush with the adjacent faces of said outside faceportions.

8. In a refractory block structure, a plurality of refractory blocks,each such block including two separable parts, one superposed upon theother, each such part including an outside face portion, an inside faceportion, and a connecting spacer portion between the two portions, andseparate spacer members interposed between the oppositeedges of theoutside face portions only, said spacer members being each as high asthe adjacent refractory blocks, the edges of the adjacent inside faceportions abutting, the outer faces of said spacer members being flushwith the adjacent faces of said outside face portions.

9. In a refractory block structure, a plurality of refractory blocks,each such block including two separate parts, one superposed upon theother, each such part including an outside face portion, an inside faceportion, and a connecting spacer portion between the two portions, andseparate spacer members interposed between the opposite edges of theoutside face portions only, said spacer members being each as high asthe adjacent refractory blocks, the edges of the adjacent inside faceportions of said blockabutting, said blocks and spacers being arrangedin a plurality of superposed rows, the blocks and spacers of eachadjacent row being staggered, whereby the separate spacer members of onerow are supported upon the blocks of the row next beneath.

10. In a refractory block structure, a plurality of refractory blocks,each such block including two separable parts, one superposed upon theother, each such part including an outside face portion, an inside faceportion, and a connecting spacer portion between the two portions, andseparate spacer members interposed betweenthe opposite edges of theoutside face portions only, said spacer members being each as high asthe adjacent refractory blocks, the edges of the adjacent inside faceportions abutting, the outer faces of said spacer members being flushwith the adjacent faces of said outside face portions, and

supporting brackets for said refractory blocks,

only a part of said blocks being so supported, the supported blocksbeing arranged in rows, with rows of unsupported blocks positioned abovethem, the blocks and spacer members of adjacent rows being in staggeredrelationship, whereby the spacer members of one row are positioned uponthe blocks of the row next beneath.

11. In a stack structure, an outside shell, a plurality of supportspositioned upon the inner face of said shell, and a lining for saidshell including a plurality of refractory blocks, each such blockincluding an outside face portion, air inside face portion, and aconnecting spacer, some of said blocks being apertured to conform tosaid supports.

12. The structure ofclaim 11 characterized by the employment of aplurality of horizontal rows of supports, the blocks of intermediaterows being supported upon the blocks engaged by said supports, theblocks of adjacent rows being staggered in relation to each other.

13. The structure of claim 11 characterized by the employment of aplurality of horizontal rows of supports, the blocks of intermediaterows being supported upon the blocks engaged by said supports, theblocks of adjacent rows being staggered in relation to each other,independent spacing members being interposed between the opposed edgesof the outside face portions of adjacent blocks, the linear width of theoutside portion of each block being slightly less than the linear widthof the inside face portions of such block. a

v 14. In a stack structure, an outside shell, a plurality of supportspositioned upon the inner face of said shell, and a lining for saidshell including a plurality of refractory blocks; each such blockincluding an outside face portion, an inside face portion, and aconnecting spacer, the blocks being staggered within the stack toprovide a tortuous air passage.

' inner face portions of the blocks establishing a 15. In a stackstructure, an outside shell, 9. plurality of supports positioned uponthe inner face of said shell, and a lining for said shell including aplurality ofv refractory blocks, each such block including an outsideface portion, an inside face 6 portion, and a connecting spacer,adjacent blocks being staggered with respect to each other;-

' 16. In a stack structure. an outside shell, a plurality of supportspositioned upon the innerlface of said shell, a lining for said shellincluding a 10 plurality of refractory blocks, each such block includingan outside face portion, an inside face portion. and a connectingspacer, the outer and inner face portions of the blocks establishing apre-heating air passage, and means for introducl5 ing air to bepre-heated to said passage, and for withdrawing pre-heated air from saidpassage;

17. In a stack structure, an outside shell, aplurality of supportspositioned upon the'inner face, of said shell, a lining for said shellincluding a, plurality of refractory blocks, each such block includingan outside face portion, an inside face portion, anda connecting spacer,the outer and pro-heating air passage, and means for introducing air tobe pre-heated to said passage, and for withdrawing pre-heated air fromsaid passage, the blocks being staggered with respect to each other tobring adjacent spacers out of vertical alinement and to provide atortuous air passage.

18. In a refractory block structure, a pair of adjacent refractoryblocks, each including an outside face portion, an inside face portion,and an integral connecting spacer'portion between the two portions, anda separate spacer member interposed between the opposite edges of theoutside face portions only, the inside face portions of adjacent blocksabutting, the outer face of said spacer being flush with the outer faceof said outside face portions.

MARK C. NEIL.

